IS : 10096 (Part 1/Sec 1) - 1983

(Reaffirmed 2000)
Edition 1.1
(1993-01)
Indian Standard
RECOMMENDATIONS FOR
INSPECTION, TESTING AND MAINTENANCE
OF RADIAL GATES AND ROPE DRUM HOISTS
PART I INSPECTION, TESTING AND ASSEMBLY AT
THE MANUFACTURING STAGE
Section I Gates

(Incorporating Amendment No. 1)

UDC 626.422.23 : 620.1

© BIS 2007

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN , 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002

Price Group 2
 IS : 10096 (Part 1/Sec 1) - 1983

Indian Standard
RECOMMENDATIONS FOR
INSPECTION, TESTING AND MAINTENANCE
OF RADIAL GATES AND ROPE DRUM HOISTS
PART I INSPECTION, TESTING AND ASSEMBLY AT
THE MANUFACTURING STAGE
Section I Gates
Hydraulic Gates and Valves Sectional Committee, BDC 56
Chairman Representing
SHRI Y. ADINARAYANA SASTRI Tungabhadra Steel Products Limited, Tungabhadra
Dam (Karnataka)
Members
SHRI G. S. ANNIGERI ( Alternate to
Shri Y. Adinarayana Sastri )
CHIEF ENGINEER (TDD) Irrigation Works, Government of Punjab, Chandigarh
DIRECTOR (M/E) ( Alternate )
SHRI R. C. CHOPRA TEXMACO Ltd, Calcutta
SHRI R. BHATTACHARYA ( Alternate )
SHRI H. C. DHINGRA Harayana State Minor Irrigation (Tubewells)
Corporation Ltd, Chandigarh
SHRI R. C. CHAUHAN ( Alternate )
DIRECTOR Central Water & Power Research Station, Pune
SHRI A. V. GOPALA KRISHNA
RAO ( Alternate )
DIRECTOR (GATES DESIGN I) Central Water & Commission, New Delhi
SHRI C. L. VERMA ( Alternate )
SHRI R. N. GUPTA Nangal Workshops, Nangal Township
SHRI N. S. CHAWLA ( Alternate )
SHRI K. K. JULKA Beas Project, Bhakra Beas Management Board,
Nangal Township
SHRI V. P. KAUSHAL ( Alternate )
MANAGING DIRECTOR Tamil Nadu Public Works Engineering Corporation
Ltd, Madras
WORKS MANAGER ( Alternate )
SHRI K. V. S. MURTHY Triveni Structurals Ltd, Naini
SHRI M. K. V. SARMA ( Alternate )
( Continued on page 2 )

© BIS 2007
BUREAU OF INDIAN STANDARDS
This publication is protected under the Indian Copyright Act (XIV of 1957) and
reproduction in whole or in part by any means except with written permission of the
publisher shall be deemed to be an infringement of copyright under the said Act.
IS : 10096 (Part 1/Sec 1) - 1983
( Continued from page 1 )
Members Representing
SHRI NARENDRA SINGH Irrigation Department, Government of Uttar
Pradesh, Lucknow
SHRI RAJ KUMAR Bharat Heavy Electricals Ltd, Bhopal
SHRI N. Y. NARASIMHAN ( Alternate )
SHRI S. K. SADHU Jessop & Co Ltd, Calcutta
SHRI S. NAG ( Alternate )
SUPERINTENDING ENGINEER Irrigation & Power Department, Government of
(PH) (CDO) Maharashtra, Nasik
SHRI R. SWARUP Central India Machinery Manufacturing Co Ltd,
Bharatpur
SHRI K. C. BAHETY ( Alternate )
SHRI M. C. TEWARI Himachal Pradesh State Electricity Board, Simla
SHRI N. VISVANATHAN National Hydroelectric Power Corporation,
New Delhi
SHRI G. RAMAN, Director General, ISI ( Ex-officio Member )
Director (Civ Engg)
Secretary
SHRI HEMANT KUMAR
Assistant Director (Civ Engg), ISI

Panel for Inspection, Testing and Maintenance of Radial Gates,

BDC 56 : P8
Convener
SHRI M. N. SHARMA Irrigation Works, Government of Punjab, Chandigarh
Members
SHRI G. S. ANNIGERI Tungabhadra Steel Products Ltd, Tungabhadra Dam
(Karnataka)
DIRECTOR (GATES DESIGNS I) Central Water Commission, New Delhi
SHRI R. N. GUPTA Nangal Workshops, Nangal Township
SHRI N. S. CHAWLA ( Alternate )
SHRI Y. R. KALRA BSL Project, Bhakra Beas Management Board,
Sundernagar (H.P.)
SHRI R. N. AGGARWAL ( Alternate )
SHRI A. K. MUKHERJEE Jessop Co Ltd, Calcutta
SUPERINTENDING ENGINEER Irrigation Department, Government of Maharashtra,
(GATES) (CDO) Bombay
SHRI R. SWARUP Central India Machinery Manufacturing Co Ltd,
Bharatpur
SHRI M. C. TEWARI Himachal Pradesh State Electricity Board,
Government of Himachal Pradesh, Simla

2
 IS : 10096 (Part 1/Sec 1) - 1983

Indian Standard
RECOMMENDATIONS FOR
INSPECTION, TESTING AND MAINTENANCE
OF RADIAL GATES AND ROPE DRUM HOISTS
PART I INSPECTION, TESTING AND ASSEMBLY AT
THE MANUFACTURING STAGE
Section I Gates

0. F O R E W O R D
0.1 This Indian Standard (Part 1/Sec 1) was adopted by the Indian
Standards Institution on 25 November 1983, after the draft finalized
by the Hydraulic Gates and Valves Sectional Committee had been
approved by the Civil Engineering Division Council.
0.2 The gates are used not only to pass large floods but also to regulate
the reservoir level during minor variations in flow. The gate, in
general is a structural steel frame consisting of end vertical girders
with properly spaced horizontal girder between them. The spacing
depends on the design water pressure and on dimensions of the gate.
The frame is held apiece by secure welding or riveting.
0.3 Reference to the following Indian Standards will be found useful in
implementation of this standard:

IS : 210-1978 Grey iron castings ( third revision )

IS : 226-1975 Structural steel (standard quality) ( fifth revision )
IS : 306-1968 Tin bronze ingots and castings ( second revision )
IS : 318-1981 Leaded tin bronze ingots and castings ( second
revision )
IS : 823-1964 Code of procedure for manual metal arc welding of
mild steel
IS : 1030-1974 Carbon steel castings for general engineering
purposes ( second revision )
IS : 1570-1961 Schedules for wrought steels for general engineering
purposes

3
IS : 10096 (Part 1/Sec 1) - 1983

IS : 2004-1978 Carbon steel forgings for general engineering

purposes ( second revision )
IS : 2062-1980 Structural steel (fusion welding quality) ( second
revision )
IS : 2595-1978 Code of practice for radiographic testing ( first
revision )
IS : 3648-1966 Hexagon fit bolts
IS : 3658-1981 Code of practice for liquid penetrant flaw detection
( first revision )
IS : 3664-1981 Code of practice for ultrasonic pulse echo testing by
contact and immersion methods ( first revision )
IS : 3703-1980 Code of practice for magnetic particle flaw detection
( first revision )
IS : 7307 (Part 1)-1974 Approval tests for welding procedures,
Part 1 Fusion welding of steel
IS : 7310 (Part 1)-1974 Approval testing for welders working to
approved welding procedures : Part 1 Fusion welding of steel
IS : 7318 (Part 1)-1974 Approval tests for welders when welding
procedure approval is not required : Part 1 Fusion welding of steel
0.4 This standard is being published in three parts. Part 1 deals with
inspection, testing and assembly at manufacturing stage, Part 2 deals
with inspection and testing at the time of erection, and Part 3 deals
with inspection, testing and maintenance after erection.
0.4.1 Part 1 is being published in two sections. Other section of this
part will cover the hoists ( under preparation ).
0.5 This edition 1.1 incorporates Amendment No. 1 (January 1993).
Side bar indicates modification of the text as the result of
incorporation of the amendment.
0.6 For the purpose of deciding whether a particular requirement of this
standard is complied with, the final value, observed or calculated,
expressing the result of a test, shall be rounded off in accordance with
IS : 2-1960*. The number of significant places retained in the rounded off
value should be the same as that of the specified value in this standard.
1. SCOPE
1.1 This standard (Part 1/Sec 1) lays down the recommendations for
inspection, testing and assembly of radial gates at the manufacturing
stage. It does not cover hoisting equipment.
*Rules for rounding off numerical values ( revised ).

4
 IS : 10096 (Part 1/Sec 1) - 1983
2. GENERAL
2.1 All materials and components used for the work shall be new and
free from defects and subject to the tolerances specified under this
standard.
2.2 Complete inspection shall be made at the place of manufacture
prior to despatch.
3. MATERIALS
3.1 All materials and components supplied by the manufacturer shall
conform to the requirements of the latest relevant Indian Standards.
In the absence of Indian Standard for any particular material or
component, other specification mutually agreed to between the
purchaser and the supplier may be used.
3.2 All materials used shall be of tested quality. Original manufac-
turer’s test certificates for bought out items such as castings, forgings
and seals, shall be furnished by the gate manufacturer to the
purchaser on demand.
3.3 Castings
3.3.1 All castings shall conform to the relevant Indian Standards.
3.3.2 Visual examination shall be done to find out the general
soundness of the castings and if required, non-destructive tests shall
be conducted on the castings.
3.3.3 Repairs of major defects in castings by welding shall not
generally be allowed, but if the strength and machinability of the
casting can be ensured, the repairing may be undertaken with the
approval of the purchaser.
3.3.4 Defective castings as permitted under 3.3.3 shall be heat-treated
after repairs by welding, where deemed essential.
3.4 Forgings
3.4.1 All forgings shall conform to the latest relevant Indian
Standards.
3.4.2 All forgings shall be suitably heat-treated according to relevant
Indian Standards.
3.4.3 Visual inspection of forgings shall be done and the finished
surface shall be smooth and free from defects. If required, non-destruc-
tive tests shall be conducted on the forgings.

5
IS : 10096 (Part 1/Sec 1) - 1983
4. WELDING
4.1 All weldings shall conform to the relevant Indian Standards and
approved electrodes shall be used.
4.2 Welding procedure for all major welds shall be drawn-up and
carried out and if required by the purchaser, test pieces may be made
to ensure the soundness of the welding.
4.3 Only tested welders shall be employed for the welding work.
4.4 Visual examination shall be carried out of all welded joints to
ensure that welding is free from:
a) cracks on the surfaces of the joints or parent metals located near
the heat affected zones,
b) undercuts in the parent metals,
c) non-uniform width of fillet joints,
d) misalignment and distortion of the welded member, and
e) irregular reinforcing beads of welds.
4.4.1 Welds found to be defective shall be subjected to non-destructive
tests to ensure soundness of welding.
4.5 Proper sequence of welding shall be followed for welding of heavy
structural parts in order to minimize distortion.
4.6 Defective welds after testing shall be removed and rewelded.
4.7 All major stress carrying welded joints shall be subjected to
suitable non-destructive testing, as specified by the purchaser.
4.8 Any item or part may be stress-relieved according to the
requirements and procedure laid down in IS : 2825-1969*. Generally
following items require stress-relieving.
a) Yoke/trunnion girders, anchor girders and trunnion brackets
where heavy welding is involved; and
b) Trunnion hub if part of the arm (structural portion) is welded to
the casting.
5. MANUFACTURING TOLERANCES
5.1 The gates and embedded parts shall be manufactured to such
accuracy and tolerances as are required for the safe and efficient
operation of the gates. Unless otherwise specified, the tolerances given
in 5.2 and 5.3 may be used as a general guide.
*Code for unfired pressure vessels.

6
 IS : 10096 (Part 1/Sec 1) - 1983
5.2 Embedded Parts
5.2.1 Deviation of any point on the face of seal seat from 2 m machined
straight edge held against it shall not exceed 0.5 mm.
5.2.2 Deviation from straightness of the wall plate shall not be more
than 2 mm in 2 metre length.
5.2.3 Offsets and gaps at any adjoining joints between seal seats,
guides, etc, shall not exceed 0.5 mm.
5.3 Gates
5.3.1 The gate leaves with stiffeners shall generally be manufactured
on a jig and fixture. The tolerance on the radius of gate leaf shall be
1
--------------- of radius or ± 10 mm whichever is less.
1 000
5.3.2 The distance between the side guide roller/guide shoes on one
side of the gate to the corresponding guide roller/guide shoes on the
other side shall not vary from dimension shown in the drawings by
more than + 0.00 mm to – 2.00 mm.
5.3.3 Parallel distance of centre line of both the trunnion bearings
from upstream bottom edge of skin plate shall not vary more than
± 3.0 mm.
5.3.4 The horizontal distance between the centre to centre of trunnions
shall not vary from the dimension shown in the drawings by more than
± 3.0 mm.
5.4 Connections — At all splices, the holes shall be match drilled. If
fit bolts are provided, holes shall be reamed at assembly.
6. SHOP ASSEMBLY AND TESTING
6.1 Gates and Embedded Parts — The anchor girder together with
the tie bars of convenient length for testing and yoke girder shall be
load-tested equivalent to 1.5 times the design load before erection. The
load shall be applied gradually by means of hydraulic jacks and the
assembly shall remain under load to enable all the observations
required by the test procedure to be made.
6.1.1 Assembly of wall plates and sill beams shall be done at shop.
6.1.2 Gates shall be assembled complete with guide rollers and trun-
nions for proper alignment and inspection. All the dimensions
specified in 5.2 and 5.3 and other central dimensions shall be checked
on assembly.

7
IS : 10096 (Part 1/Sec 1) - 1983
6.1.3 Side guide rollers may be shimmed, if necessary, to maintain the
required tolerances as specified in 5.3.2.
6.2 Seals — Seals may be assembled either at shop or during erection
according to the convenience of the manufacturer. The holes in seals
shall be match drilled with seals base and clamps.
6.3 Ballast — Ballast if required, can be provided either at shop or at
site.
6.4 Marking
6.4.1 All erection marks shall be hard-punched.
6.4.2 All the components shall be match-marked before dismantling.
7. CLEANING AND PAINTING
7.1 Surface shall be cleaned thoroughly, preferably by sand/shot
blasting.
7.2 Painting shall be as specified by the purchaser and the application
procedure shall be as recommended by the paint manufacturer.

8
Bureau of Indian Standards
BIS is a statutory institution established under the Bureau of Indian Standards Act, 1986 to promote
harmonious development of the activities of standardization, marking and quality certification of
goods and attending to connected matters in the country.
Copyright
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designations. Enquiries relating to copyright be addressed to the Director (Publications), BIS.
Review of Indian Standards
Amendments are issued to standards as the need arises on the basis of comments. Standards are also
reviewed periodically; a standard along with amendments is reaffirmed when such review indicates
that no changes are needed; if the review indicates that changes are needed, it is taken up for
revision. Users of Indian Standards should ascertain that they are in possession of the latest
amendments or edition by referring to the latest issue of ‘BIS Catalogue’ and ‘Standards : Monthly
Additions’.
This Indian Standard has been developed by Technical Committee : BDC 56 and amended by RVD 12

Amendments Issued Since Publication

Amend No. Date of Issue
Amd. No. 1 January 1993

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